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Supplement 900-1 002 Date: 12-94 lnsett with- Tile: YD Generators and Controls Service Manual Number: 900-0184 Date: 11-83 ~~ ~ ~ ~ This supplement to the YD Service Manual adds information specific to the Onan PROTEC series of YD PTO AC generator/voltage regulator systems. NOTE: The YD PTO product referred to in the YD Service Manual is an earlier Onan product, no longer being manufactured. CONTENTS OF SUPPLEMENT TITLE PAGE GeneratorNoltage Regulator Troubleshooting ........................................ 1 GeneratodRegulator Tests ........................................................ .5 12/15 KW Generator Meter/Breaker Panel Schematic Diagram (61 5-0426) .............. 13 16/20,20/24 KW Generator MeterBreaker Panel Schematic Diagram (61 5-0427) ........ 14 24/30,30/35 KW Generator MeterBreaker Panel Schematic Diagram (61 5-0428) ....... .I5 YD PTO AC Generator Wiring Diagram (61 2-6678) .................................. .I6 GENERATOWVOLTAGE REGULATOR TROUBLESHOOTING This section contains troubleshooting information for the generator and its electronic voltage regulator. Determine the problem and then re- fer to the appropriate flow chart (A, 8, Cy D, or E) for troubleshooting procedures. A. NO AC OUTPUT VOLTAGE AT RATED RPM. B. UNSTABLE OUTPUT VOLTAGE, EN- GINE SPEED STABLE. C. OUTPUT VOLTAGE TOO HIGH OR LOW D. EXCITER FIELD BREAKER TRIPS E. UNBALANCED GENERATOR OUTPUT VOLTAGE 1 To troubleshoot a problem, start at upper left comer of the chart related to the problem, and answer all questions either YES or NO. Follow the chart until the problem is found, performing referenced Adjustment and Test procedures following the Flow Charts. Referenced components in the Flow Charts and Adjustment and Test procedures can be found on the schematic and wiring diagrams found in this supplement, and in the assembly drawings found in the lnstallation Manual. NOTE Generator disassembly/assembly procedures and PROTEC series YD PTO generator configurations may be found in the YD Service Manual (900-0184) and in the PROTEC Opera- tor’s ManuaI (929-0100) and Installation Manual (-).
FLOW CHART A. NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM START Is control panel field breaker CB21 on? and check continuity with ohmmeter. Is breaker open? no .) Push to reset breaker. Does generator AC output voltage build up? Yes - I no 3 of VR215 to 10 VAG or more? (TEST A) I Yes across WE1 terminals 4 and 5 5 VDC or more? I Yes Check exciter fidd wiring Replace bad wiring. 1 Check exciter field winding Replace defective If voltage is unstable, high or low, or causes breaker to trip, see Flow Charts B, C, D or E. Flash exciter fidd per TEST C. Does generator output voltage build up? I no 1 Check diodes CR1 through CR6 on rotor per TEST F. Replace if bad. Check exciter field wiring for shorts per TEST L Replace bad wiring. Check exciter rotor winding per TEST H. Replace if bad. I I Replace fhe regulator PC board per procedure E if defective. -1 Conbct wifh high vol&ge can cause severe personal injury or death. Do nof touch any exposed wiring or components wiih any parf of the body, clothing, tool or jewelry-. Do not use non-insulated tools inside the control. Sbnd on an insulating mat or dry woodplaffom when the control doors are open. -1 A newprinfedcircuit boardcan be dam- aged bymalrUnctioning components within the control. Do not insiall the new PC board until all other problems have been located and corrected. 2 Check generator rotor winding per TEST K. Replace if bad. I 1 Check generator stator windings I Der TEST J. ReDlace if bad. I
Page 1 and 2: Caution: This document contains mix
Page 3: The following symbols in this manua
Page 7 and 8: STMT Check exciter stator winding p
Page 9 and 10: -1 Contact with high voltage can ca
Page 11 and 12: The preferred test is with a megger
Page 13 and 14: are given in Table 1 (lead length b
Page 15 and 16: L - Wiring Harness Check Stop engin
Page 17: T I I I I I I I - I I I I I I I I I
Page 21 and 22: GENERAL This manual contains troubl
Page 23 and 24: generator adapter. The brushless ex
Page 25 and 26: Is control panel field breaker CB21
Page 27 and 28: FLOW CHART D. AC OUTPUT VOLTAGE BUI
Page 29 and 30: GENERAL All of the following Adjust
Page 31 and 32: . FIGURE 6. MSHlNGTHEFiELD voltage
Page 33 and 34: MULTIMETER FIGURE 11. SCR VOLTAGE T
Page 35 and 36: TABLE 2 RESISTANCE VALUES FOR ROTOR
Page 37 and 38: VOLTAGE REGULATOR The line-voltage
Page 39 and 40: VI v2 v3 v4 - VI v2 v4 VI v2 \R v4
Page 41 and 42: START Is control panel field breake
Page 43 and 44: . FLOW CHART D. EXCITER FIELD BREAK
Page 45 and 46: GENERAL All of the following Adjust
Page 47 and 48: The winding schematic (Figure 25) s
Page 49 and 50: CONTACT ONE PROD TO EACE OF M E FIE
Page 51 and 52: [a1 RECONNECTION WIRE W12 Figure 36
Page 53 and 54: 1201240 VOLT, 1 PHASE, 60 HERTZ NAM
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ASSEMBLY 9. Torque down rotor-throu
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. Starting Watts ..................
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WIRING CONNECTIONS, 15-25 kW SINGLE
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PERIODIC SERVICE AND INSPECTION SER
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I I I I CYRZI-2 I 7821-1 I - I t I
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NOTE: For detailed troubleshooting
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3. Removesix5/16x l-inch capscrewsa
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4. Remove end bell by tapping upwar
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9. Remove rotor and fan .by using a
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14. If bearing, shaft, or oil seal
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AC .AMMETERS WATER TEMPERATURE GAU
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ENGINE CONTROL SYST.EM OPERATION De
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Umlt cranking 15 to 20reconds to co
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RADIATOR-COOLED DIESEL SETS The con
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Start-Disconnect Sequence When cran
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a a W a 9 W z f 66 6 b w a 3 0 E
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START Does fuel transfer pump El an
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CONTROL COMPONENT CHECKOUT The foll
Page 91 and 92:
WIRING DIAGRAMS The wiring and sche
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I I I L I I m 74
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I 1 ' t I I U
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IW I- CE o_ u) z I It I 3 w
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I I I I I I I I 3 $1 :I a 1 I I tl
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P 83
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- --1 I" .- I . I - 1 85
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87 ~ " - .I \ e 6 a i- z 0 0 a E a
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I I I I I I I I I 7 6 Et 4 3 2 I RE
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Onan Corporation 1400 73rd Avenue N
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